Electrolytic Cooling Water Conductivity Regulation
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Solution Overview
Problem
The existing cooling water recirculation systems face issues with conductivity regulation, leading to excessive water wastage, energy inefficiency, and electrode degradation due to abrupt changes in water hardness, which causes the system to stop and requires complete water change, resulting in pipe leakage and reduced descaling performance.
Innovation Solution
A system and method that includes an electrolytic device with a conductivity probe and controller to monitor and regulate the conductivity of cooling water by adjusting the electrolysis current and polarity reversal timing, allowing continuous operation, preventing over/under electrolysis, and maintaining optimal conductivity within a range of 700 to 2500 µS/cm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the cooling water recirculation system operates without conductivity regulation, then the system can run continuously, but the dissolved solids become concentrated due to evaporation causing scale deposition and microorganism multiplication
Solution Approach 1:
The system employs a conductivity probe to continuously monitor the conductivity of cooling water and provides feedback to the controller. When conductivity exceeds a predetermined threshold, the controller automatically activates the electrolytic device to treat the water, thereby maintaining heat transfer efficiency without interrupting continuous operation.
Solution Approach 2:
The electrolytic device automatically treats the cooling water when conductivity thresholds are exceeded, eliminating the need for manual intervention or complete system shutdown. The system self-regulates by activating electrolysis only when needed, based on real-time conductivity monitoring.
2Reliability
If the system stops and changes entire cooling water when conductivity exceeds threshold, then scale deposition is prevented, but excessive water wastage and energy wastage occur
Solution Approach 1:
Instead of draining and replacing the entire cooling water system when conductivity exceeds thresholds, the electrolytic device extracts and removes dissolved solids through electrolysis. The electrolytic device deposits mineral contents as precipitated scale on electrodes, which are then periodically dislodged and removed, allowing the bulk cooling water to be retained and recirculated.
Solution Approach 2:
The system changes the physical-chemical parameters of the cooling water in-place through electrolysis. By applying electrical current, dissolved solids are transformed from soluble ions into insoluble precipitates that can be easily removed from the water stream without requiring complete water replacement.
3Reliability
If high amperage is applied for electrolysis to handle high conductivity water, then descaling performance is improved, but electrode lifespan is reduced and electricity consumption increases
Solution Approach 1:
The system dynamically adjusts the amperage applied to the electrolytic device based on real-time conductivity measurements. The controller modulates the electrical current to match the actual conductivity level of the cooling water, applying higher amperage only when conductivity is high and scale deposition risk is elevated, and reducing or suspending amperage when conductivity is within acceptable ranges.
Solution Approach 2:
The system changes the electrical parameters (amperage, voltage) of the electrolytic device based on measured conductivity values. By dynamically adjusting these electrical parameters to match the actual water conditions, the system achieves effective descaling when needed while minimizing electricity consumption and electrode wear during normal operating conditions.
4Ease of operation
If conductivity is not regulated, then the system operation is simple, but over electrolysis causes pipe leakage due to corrosion and under electrolysis degrades descaling performance
Solution Approach 1:
The conductivity probe provides continuous feedback on the actual conductivity level of the cooling water to the controller. This feedback enables the controller to precisely control the electrolytic process, activating it only when conductivity exceeds thresholds and deactivating it when conductivity is within acceptable ranges, thereby preventing both over-electrolysis and under-electrolysis.
Solution Approach 2:
The system automatically self-regulates the electrolytic process based on real-time conductivity monitoring, eliminating the need for manual control or complex operational procedures. The controller autonomously decides when to activate or deactivate the electrolytic device based on predetermined conductivity thresholds, maintaining pipe integrity and descaling performance through automated parameter adjustment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables continuous operation of the cooling water recirculation system, reduces water and electricity consumption, prolongs electrode lifespan, and maintains effective descaling performance by dynamically adjusting electrolysis parameters based on conductivity levels.
Implementation Method 1
A recent method of limiting scale deposition and microorganism multiplication are achieved by electrolysis, wherein a pair of electrodes is used for depositing mineral contents contained in the cooling water as precipitated scale and dislodging such scale by electrode polarity reversal at a predetermined time interval
Implementation Method 2
a conductivity probe provided along the outflow line for regulating current applied for electrolysis of the cooling water by measuring a conductivity of the cooling water along the outflow line
Implementation Method 3
the controller comprises a conductivity device for monitoring the value of voltage and the value of current between the pair of electrodes and for calculating the conductivity of the cooling water based on the monitored values of voltage and current
Implementation Method 4
a discharge outlet comprising a valve, whereby the conductivity device regulates the amount of discharge of the cooling water from the electrolytic chamber by regulating the duration of discharge of the cooling water via the valve
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
There is provided a system and method for regulating conductivity of cooling water in a recirculation route of a cooling water recirculation system through which the cooling water is circulated for removing scale from the cooling water. The system comprises an electrolytic device connectable to the cooling water recirculation system for performing electrolysis on the cooling water and a controller. The controller is for controlling the electrolysis of the cooling water in an electrolytic chamber of the electrolytic device for depositing ions in the cooling water as scale on the surface of one of a pair of electrodes of the electrolytic device and for dislodging the scale deposited thereon, monitoring a value of voltage and a value of current between the pair of electrodes, calculating a conductivity of the cooling water based on the monitored values of voltage and current, and regulating an amount of discharge of the cooling water from the electrolytic chamber based on the calculated conductivity of the cooling water, whereby the scale is removed with the cooling water that is being discharged and the cooling water that is being electrolyzed is directed back to the recirculation route of the cooling water recirculation system for circulation.